Instrument device manipulator with roll mechanism

ABSTRACT

An instrument device manipulator (IDM) is attached to a surgical arm of a robotic system and comprises a surgical tool holder and an outer housing. The surgical tool holder includes an attachment interface that can secure a surgical tool in a front-mount configuration (where the attachment interface is on a face opposite of a proximal extension of the surgical tool) or a back-mount configuration (where the attachment interface is on the same face as the proximal extension of the surgical tool). The surgical tool holder may rotate continuously within the outer housing. In a back-mount configuration, the surgical tool holder may have a passage that receives the proximal extension of the tool and allows free rotation of the proximal extension about the rotational axis. A surgical drape separates the IDM and robotic arm from a tool, while allowing electrical and/or optical signals to pass therebetween.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/216,239 filed Sep. 9, 2015, which is incorporated by reference hereinin its entirety.

The subject matter of the present application is related to U.S. patentapplication Ser. No. 14/523,760, filed Oct. 24, 2014; U.S. patentapplication Ser. No. 14/542,403, filed Nov. 14, 2014 (which claims thebenefit of U.S. Provisional Application No. 61/895,315, filed on Oct.24, 2013); U.S. Provisional Application No. 62/019,816, filed Jul. 1,2014; U.S. Provisional Patent Application No. 62/037,520, filed Aug. 14,2014; U.S. Provisional Patent Application No. 62/057,936, filed Sep. 30,2014; U.S. Provisional Patent Application No. 62/134,366, filed Mar. 17,2015; and U.S. Provisional Patent Application No. 62/184,741, filed Jun.25, 2015. Each of the foregoing is incorporated herein by reference inits entirety.

BACKGROUND

This description generally relates to surgical robotics, andparticularly to an instrument device manipulator capable of rotating asurgical tool.

Robotic technologies have a range of applications. In particular,robotic arms help complete tasks that a human would normally perform.For example, factories use robotic arms to manufacture automobiles andconsumer electronics products. Additionally, scientific facilities userobotic arms to automate laboratory procedures such as transportingmicroplates. In the medical field, physicians have started using roboticarms to help perform surgical procedures.

In a surgical robotic system, a robotic arm is connected to aninstrument device manipulator, e.g., at the end of the robotic arm, andis capable of moving the instrument device manipulator into any positionwithin a defined work space. The instrument device manipulator can bedetachably coupled to a surgical tool, such as a steerable catheter forendoscopic applications or any of a variety of laparoscopic tools. Theinstrument device manipulator imparts motion from the robotic arm tocontrol the position of the surgical tool, and it may also activatecontrols on the tool, such as pull wires to steer a catheter.Additionally, the instrument device manipulator may be electricallyand/or optically coupled to the tool to provide power, light, or controlsignals, and may receive data from the tool such as a video stream froma camera on the tool.

To robotically drive an endoscope or other elongate surgical tool, it isoften desirable to both articulate in a desired linear direction and“roll” in a desired angular direction. As used herein, the term “roll”means to rotate the endoluminal or other elongate surgical tool about alongitudinal axis of the surgical tool. In current elongated medicaldevices, roll in the device shafts is often achieved at the expense ofpull-cable management. For example, in some laparoscopic devices on themarket, roll of the device shaft may be accomplished by simply twistingthe actuation pull wires (used for manipulation of the device's endeffectors and/or wrist) around each other at the same rate as the shaft.Due to mechanically-limited revolutions in either direction, the twistin the cables show little to no adverse effect on either roll or graspermanipulation. Nevertheless, this lack of pull-wire management results innoticeably varying levels of friction throughout the shaft rotations.The accumulated friction steadily increases with each rotation until thepull wires are tightly bound around one another, much like a wire-rope,until the pull wires may no longer be able to overcome the resultingfriction to exert tension on the device's end effectors and/or wrist.

In some products, articulation and roll are de-coupled using a roboticouter “sheath” to enable pitch and yaw articulation, while a flexiblelaparoscopic tool controls insertion roll and end-effector actuation.However, this results in an unnecessarily large system with two separatemodules controlling different degrees of freedom. Separate modulescomplicate the pre-operative workflow because the operator must nowregister two sets of devices relative to the patient. In manualendoscopes, knobs and dials actuate the distal tip of the scope whilerotation of the shaft is achieved by twisting the entire proximal end ofthe tool. As a result, when rolling the scope, the operator is forced tocontort into an uncomfortable, compensatory position in order to operatethe knobs and dials. These contortions are undesirable; thus,necessitating a different approach.

Accordingly, there is a need for surgical tool manipulators that arecapable of “rolling” endoluminal and other elongate surgical toolswithout compromise to the tools actuation and articulation capabilities.There is a further need to provide surgical drapes which are compatiblewith such manipulators.

SUMMARY

Embodiments of the invention comprise instrument device manipulators(IDM) for attachment to a surgical arm of a robotic surgical system. TheIDMs are configured to attach a surgical tool to the robotic surgicalarm in a manner that allows the surgical tool to be continuously rotatedor “rolled” about an axis of the surgical tool. The IDM comprises a baseconfigured to be removeably or fixedly attach to the robotic surgicalarm and a surgical tool holder assembly attached to the base. Thesurgical tool holder assembly comprises a surgical tool holder which isrotatably secured within the surgical tool holder assembly. The surgicaltool holder secures a surgical tool via an attachment interface suchthat the surgical tool will rotate together with the surgical toolholder. The surgical tool holder further comprises a passage configuredto receive a proximal extension of the surgical tool and allow freerotation of the surgical tool relative to the base. The surgical toolholder includes one or more drive mechanisms for rotating the surgicaltool holder relative to the base.

In certain embodiments, the attachment interface of the surgical toolholder includes one or more torque couplers which are configured toengage and drive a plurality of end-effectors of the surgical tool whenthe surgical tool is secured to the surgical tool holder. The IDMfurther comprises a plurality of slip rings to communicatively couplethe base to the surgical tool holder in order to power the one or moredrive mechanisms.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates a surgical robotic system, according to oneembodiment.

FIG. 2 illustrates a command console for a surgical robotic system,according to one embodiment.

FIG. 3 illustrates a perspective view of an instrument devicemanipulator for a surgical robotic system, according to one embodiment.

FIG. 4 illustrates a side view of the instrument device manipulator ofFIG. 3, according to one embodiment.

FIG. 5 illustrates a front-perspective exploded view of an examplesurgical tool secured to the instrument device manipulator of FIG. 3,according to one embodiment.

FIG. 6 illustrates a back-perspective exploded view of an examplesurgical tool secured to the instrument device manipulator of FIG. 3,according to one embodiment.

FIG. 7 illustrates a zoomed-in, perspective view of an actuationmechanism for engagement and disengagement of a surgical tool from asurgical tool holder, according to one embodiment.

FIGS. 8A and 8B illustrate a process of engaging and disengaging asurgical tool from a sterile adapter, according to one embodiment.

FIGS. 9A and 9B illustrate a process of engaging and disengaging asurgical tool from a sterile adapter, according to an additionalembodiment.

FIG. 10A illustrates a perspective view of a mechanism for rolling asurgical tool holder within an instrument device manipulator, accordingto one embodiment.

FIG. 10B illustrates a cross-sectional view of an instrument devicemanipulator, according to one embodiment.

FIGS. 11A and 11B illustrate partially exploded, perspective views ofthe internal components of an instrument device manipulator and certainelectrical components thereof, according to one embodiment.

FIG. 12 illustrates a zoomed-in, perspective view of electricalcomponents of an instrument device manipulator for roll indexing thesurgical tool holder, according to one embodiment.

FIG. 13 illustrates a cross-sectional view of a surgical drape for aninstrument device manipulator for a surgical robotics system, accordingto one embodiment.

FIG. 14 illustrates a cross-sectional view of reciprocal matinginterfaces of a surgical drape for a surgical tool holder, according toone embodiment.

FIG. 15 illustrates a cross-sectional view of sterile adapters of asurgical drape for an instrument device manipulator, according to oneembodiment.

FIG. 16 illustrates a cross-sectional view of a surgical drape for aninstrument device manipulator, according to an additional embodiment.

FIG. 17 illustrates an optical interface for power and data transmissionbetween a surgical tool and an instrument device manipulator, accordingto one embodiment.

The figures depict embodiments of the present invention for purposes ofillustration only. One skilled in the art will readily recognize fromthe following discussion that alternative embodiments of the structuresand methods illustrated herein may be employed without departing fromthe principles of the invention described herein.

DETAILED DESCRIPTION I. Surgical Robotic System

FIG. 1 illustrates an embodiment of a surgical robotic system 100. Thesurgical robotic system 100 includes a base 101 coupled to one or morerobotic arms, e.g., robotic arm 102. The base 101 is communicativelycoupled to a command console, which is further described herein withreference to FIG. 2. The base 101 can be positioned such that therobotic arm 102 has access to perform a surgical procedure on a patient,while a user such as a physician may control the surgical robotic system100 from the comfort of the command console. In some embodiments, thebase 101 may be coupled to a surgical operating table or bed forsupporting the patient. Though not shown in FIG. 1 for purposes ofclarity, the base 101 may include subsystems such as controlelectronics, pneumatics, power sources, optical sources, and the like.The robotic arm 102 includes multiple arm segments 110 coupled at joints111, which provides the robotic arm 102 multiple degrees of freedom,e.g., seven degrees of freedom corresponding to seven arm segments. Thebase 101 may contain a source of power 112, pneumatic pressure 113, andcontrol and sensor electronics 114—including components such as acentral processing unit, data bus, control circuitry, and memory—andrelated actuators such as motors to move the robotic arm 102. Theelectronics 114 in the base 101 may also process and transmit controlsignals communicated from the command console.

In some embodiments, the base 101 includes wheels 115 to transport thesurgical robotic system 100. Mobility of the surgical robotic system 100helps accommodate space constraints in a surgical operating room as wellas facilitate appropriate positioning and movement of surgicalequipment. Further, the mobility allows the robotic arms 102 to beconfigured such that the robotic arms 102 do not interfere with thepatient, physician, anesthesiologist, or any other equipment. Duringprocedures, a user may control the robotic arms 102 using controldevices such as the command console.

In some embodiments, the robotic arm 102 includes set up joints that usea combination of brakes and counter-balances to maintain a position ofthe robotic arm 102. The counter-balances may include gas springs orcoil springs. The brakes, e.g., fail safe brakes, may include mechanicaland/or electrical components. Further, the robotic arms 102 may begravity-assisted passive support type robotic arms.

Each robotic arm 102 may be coupled to an instrument device manipulator(IDM) 117 using a mechanism changer interface (MCI) 116. The IDM 117 canbe removed and replaced with a different type of IDM, for example, afirst type of IDM manipulates an endoscope, while a second type of IDMmanipulates a laparoscope. The MCI 116 includes connectors to transferpneumatic pressure, electrical power, electrical signals, and opticalsignals from the robotic arm 102 to the IDM 117. The MCI 116 can be aset screw or base plate connector. The IDM 117 manipulates surgicalinstruments such as the endoscope 118 using techniques including directdrive, harmonic drive, geared drives, belts and pulleys, magneticdrives, and the like. The MCI 116 is interchangeable based on the typeof IDM 117 and can be customized for a certain type of surgicalprocedure. The robotic 102 arm can include a joint level torque sensingand a wrist at a distal end, such as the KUKA AG® LBR5 robotic arm.

The endoscope 118 is a tubular and flexible surgical instrument that isinserted into the anatomy of a patient to capture images of the anatomy(e.g., body tissue). In particular, the endoscope 118 includes one ormore imaging devices (e.g., cameras or sensors) that capture the images.The imaging devices may include one or more optical components such asan optical fiber, fiber array, or lens. The optical components movealong with the tip of the endoscope 118 such that movement of the tip ofthe endoscope 118 results in changes to the images captured by theimaging devices. While an endoscope is used as the primary examplethroughout, it is understood that the surgical robotic system 100 may beused with a variety of surgical instruments.

In some embodiments, robotic arms 102 of the surgical robotic system 100manipulate the endoscope 118 using elongate movement members. Theelongate movement members may include pull-wires, also referred to aspull or push wires, cables, fibers, or flexible shafts. For example, therobotic arms 102 actuate multiple pull-wires coupled to the endoscope118 to deflect the tip of the endoscope 118. The pull-wires may includeboth metallic and non-metallic materials such as stainless steel,Kevlar, tungsten, carbon fiber, and the like. The endoscope 118 mayexhibit nonlinear behavior in response to forces applied by the elongatemovement members. The nonlinear behavior may be based on stiffness andcompressibility of the endoscope 118, as well as variability in slack orstiffness between different elongate movement members.

The surgical robotic system 100 includes a controller 120, for example,a computer processor. The controller 120 includes a calibration module125, image registration module 130, and a calibration store 135. Thecalibration module 125 can characterize the nonlinear behavior using amodel with piecewise linear responses along with parameters such asslopes, hystereses, and dead zone values. The surgical robotic system100 can more accurately control an endoscope 118 by determining accuratevalues of the parameters. In some embodiments, some or all functionalityof the controller 120 is performed outside the surgical robotic system100, for example, on another computer system or server communicativelycoupled to the surgical robotic system 100.

II. Command Console

FIG. 2 illustrates a command console 200 for a surgical robotic system100 according to one embodiment. The command console 200 includes aconsole base 201, display modules 202, e.g., monitors, and controlmodules, e.g., a keyboard 203 and joystick 204. In some embodiments, oneor more of the command module 200 functionality may be integrated into abase 101 of the surgical robotic system 100 or another systemcommunicatively coupled to the surgical robotic system 100. A user 205,e.g., a physician, remotely controls the surgical robotic system 100from an ergonomic position using the command console 200.

The console base 201 may include a central processing unit, a memoryunit, a data bus, and associated data communication ports that areresponsible for interpreting and processing signals such as cameraimagery and tracking sensor data, e.g., from the endoscope 118 shown inFIG. 1. In some embodiments, both the console base 201 and the base 101perform signal processing for load-balancing. The console base 201 mayalso process commands and instructions provided by the user 205 throughthe control modules 203 and 204. In addition to the keyboard 203 andjoystick 204 shown in FIG. 2, the control modules may include otherdevices, for example, computer mice, track pads, trackballs, controlpads, video game controllers, and sensors (e.g., motion sensors orcameras) that capture hand gestures and finger gestures.

The user 205 can control a surgical instrument such as the endoscope 118using the command console 200 in a velocity mode or position controlmode. In velocity mode, the user 205 directly controls pitch and yawmotion of a distal end of the endoscope 118 based on direct manualcontrol using the control modules. For example, movement on the joystick204 may be mapped to yaw and pitch movement in the distal end of theendoscope 118. The joystick 204 can provide haptic feedback to the user205. For example, the joystick 204 vibrates to indicate that theendoscope 118 cannot further translate or rotate in a certain direction.The command console 200 can also provide visual feedback (e.g., pop-upmessages) and/or audio feedback (e.g., beeping) to indicate that theendoscope 118 has reached maximum translation or rotation.

In position control mode, the command console 200 uses athree-dimensional (3D) map of a patient and pre-determined computermodels of the patient to control a surgical instrument, e.g., theendoscope 118. The command console 200 provides control signals torobotic arms 102 of the surgical robotic system 100 to manipulate theendoscope 118 to a target location. Due to the reliance on the 3D map,position control mode requires accurate mapping of the anatomy of thepatient.

In some embodiments, users 205 can manually manipulate robotic arms 102of the surgical robotic system 100 without using the command console200. During setup in a surgical operating room, the users 205 may movethe robotic arms 102, endoscopes 118, and other surgical equipment toaccess a patient. The surgical robotic system 100 may rely on forcefeedback and inertia control from the users 205 to determine appropriateconfiguration of the robotic arms 102 and equipment.

The display modules 202 may include electronic monitors, virtual realityviewing devices, e.g., goggles or glasses, and/or other means of displaydevices. In some embodiments, the display modules 202 are integratedwith the control modules, for example, as a tablet device with atouchscreen. Further, the user 205 can both view data and input commandsto the surgical robotic system 100 using the integrated display modules202 and control modules.

The display modules 202 can display 3D images using a stereoscopicdevice, e.g., a visor or goggle. The 3D images provide an “endo view”(i.e., endoscopic view), which is a computer 3D model illustrating theanatomy of a patient. The “endo view” provides a virtual environment ofthe patient's interior and an expected location of an endoscope 118inside the patient. A user 205 compares the “endo view” model to actualimages captured by a camera to help mentally orient and confirm that theendoscope 118 is in the correct—or approximately correct—location withinthe patient. The “endo view” provides information about anatomicalstructures, e.g., the shape of an intestine or colon of the patient,around the distal end of the endoscope 118. The display modules 202 cansimultaneously display the 3D model and computerized tomography (CT)scans of the anatomy the around distal end of the endoscope 118.Further, the display modules 202 may overlay pre-determined optimalnavigation paths of the endoscope 118 on the 3D model and CT scans.

In some embodiments, a model of the endoscope 118 is displayed with the3D models to help indicate a status of a surgical procedure. Forexample, the CT scans identify a lesion in the anatomy where a biopsymay be necessary. During operation, the display modules 202 may show areference image captured by the endoscope 118 corresponding to thecurrent location of the endoscope 118. The display modules 202 mayautomatically display different views of the model of the endoscope 118depending on user settings and a particular surgical procedure. Forexample, the display modules 202 show an overhead fluoroscopic view ofthe endoscope 118 during a navigation step as the endoscope 118approaches an operative region of a patient.

III. Instrument Device Manipulator

FIG. 3 illustrates a perspective view of an instrument devicemanipulator (IDM) 300 for a surgical robotic system, and FIG. 4 is aside view of the IDM 300, according to one embodiment. The IDM 300 isconfigured to attach a surgical tool to a robotic surgical arm in amanner that allows the surgical tool to be continuously rotated or“rolled” about an axis of the surgical tool. The IDM 300 includes a base302 and a surgical tool holder assembly 304. The surgical tool holderassembly 304 further includes an outer housing 306, a surgical toolholder 308, an attachment interface 310, a passage 312, and a pluralityof torque couplers 314. The IDM 300 may be used with a variety ofsurgical tools (not shown in FIG. 3), which may include a housing and anelongated body, and which may be for a laparoscope, an endoscope, orother types of end-effectors of surgical instruments.

The base 302 removeably or fixedly mounts the IDM 300 to a surgicalrobotic arm of a surgical robotic system. In the embodiment of FIG. 3,the base 302 is fixedly attached to the outer housing 306 of thesurgical tool holder assembly 304. In alternate embodiments, the base302 may be structured to include a platform which is adapted torotatably receive the surgical tool holder 308 on the face opposite fromthe attachment interface 310. The platform may include a passage alignedwith the passage 312 to receive the elongated body of the surgical tooland, in some embodiments, an additional elongated body of a secondsurgical tool mounted coaxially with the first surgical tool.

The surgical tool holder assembly 304 is configured to secure a surgicaltool to the IDM 300 and rotate the surgical tool relative to the base302. Mechanical and electrical connections are provided from thesurgical arm to the base 302 and then to the surgical tool holderassembly 304 to rotate the surgical tool holder 308 relative to theouter housing 306 and to manipulate and/or deliver power and/or signalsfrom the surgical arm to the surgical tool holder 308 and ultimately tothe surgical tool. Signals may include signals for pneumatic pressure,electrical power, electrical signals, and/or optical signals.

The outer housing 306 provides support for the surgical tool holderassembly 304 with respect to the base 302. The outer housing 306 isfixedly attached to the base 302 such that it remains stationaryrelative to the base 302, while allowing the surgical tool holder 308 torotate freely relative to the outer housing 306. In the embodiment ofFIG. 3, the outer housing 306 is cylindrical in shape and fullycircumscribes the surgical tool holder 308. The outer housing 306 may becomposed of rigid materials (e.g., metals or hard plastics). Inalternate embodiments, the shape of the housing may vary.

The surgical tool holder 308 secures a surgical tool to the IDM 300 viathe attachment interface 310. The surgical tool holder 308 is capable ofrotating independent of the outer housing 306. The surgical tool holder308 rotates about a rotational axis 316, which co-axially aligns withthe elongated body of a surgical tool such that the surgical toolrotates with the surgical tool holder 308.

The attachment interface 310 is a face of the surgical tool holder 308that attaches to the surgical tool. The attachment interface 310includes a first portion of an attachment mechanism that reciprocallymates with a second portion of the attachment mechanism located on thesurgical tool, which will be discussed in greater detail with regards toFIGS. 8A and 8B. The attachment interface 310 comprises a plurality oftorque couplers 314 that protrude outwards from the attachment interface310 and engage with respective instrument inputs on the surgical tool.In some embodiments, a surgical drape, coupled to a sterile adapter, maybe used to create a sterile boundary between the IDM 300 and thesurgical tool. In these embodiments, the sterile adapter may bepositioned between the attachment interface 310 and the surgical toolwhen the surgical tool is secured to the IDM 300 such that the surgicaldrape separates the surgical tool and the patient from the IDM 300 andthe surgical robotics system.

The passage 312 is configured to receive the elongated body of asurgical tool when the surgical tool is secured to the attachmentinterface 310. In the embodiment of FIG. 3, the passage 312 isco-axially aligned with the longitudinal axis of the elongated body ofthe surgical tool and the rotational axis 316 of the surgical toolholder 308. The passage 312 allows the elongated body of the surgicaltool to freely rotate within the passage 312. This configuration allowsthe surgical tool to be continuously rotated or rolled about therotational axis 316 in either direction with minimal or no restrictions.

The plurality of torque couplers 314 are configured to engage and drivethe components of the surgical tool when the surgical tool is secured tothe surgical tool holder 308. Each torque coupler 314 is inserted into arespective instrument input located on the surgical tool. The pluralityof torque couplers 314 may also serve to maintain rotational alignmentbetween the surgical tool and the surgical tool holder 308. Asillustrated in FIG. 3, each torque coupler 314 is shaped as acylindrical protrusion that protrudes outwards from the attachmentinterface 310. Notches 318 may be arranged along the outer surface areaof the cylindrical protrusion. In some embodiments, the arrangement ofthe notches 318 creates a spline interface. The instrument inputs on thesurgical tool are configured to have a complementary geometry to thetorque couplers 314. For example, while not shown in FIG. 3, theinstrument inputs of the surgical tool may be cylindrical in shape andhave a plurality of ridges that reciprocally mate with the plurality ofnotches 318 on each torque coupler 314 and thus impart a torque on thenotches 318. In alternate embodiments, the top face of the cylindricalprotrusion may include the plurality of notches 318 configured to matewith a plurality of ridges in respective instrument inputs. In thisconfiguration, each torque coupler 314 fully engages with its respectiveinstrument input.

Additionally, each torque coupler 314 may be coupled to a spring thatallows the torque coupler to translate. In the embodiment of FIG. 3, thespring causes each torque coupler 314 to be biased to spring outwardsaway from the attachment interface 310. The spring is configured tocreate translation in an axial direction, i.e., protract away from theattachment interface 310 and retract towards the surgical tool holder308. In some embodiments, each torque coupler 314 is capable ofpartially retracting into the surgical tool holder 308. In otherembodiments, each torque coupler 314 is capable of fully retracting intothe surgical tool holder 308 such that the effective height of eachtorque coupler is zero relative to the attachment interface 310. In theembodiment of FIG. 3, the translation of each torque coupler 314 isactuated by an actuation mechanism, which will be described in furtherdetail with regards to FIGS. 7-8. In various embodiments, each torquecoupler 314 may be coupled to a single spring, a plurality of springs,or a respective spring for each torque coupler.

In addition, each torque coupler 314 is driven by a respective actuatorthat causes the torque coupler to rotate in either direction. Thus, onceengaged with an instrument input, each torque coupler 314 is capable oftransmitting power to tighten or loosen pull-wires within a surgicaltool, thereby manipulating a surgical tool's end-effectors. In theembodiment of FIG. 3, the IDM 300 includes five torque couplers 314, butthe number may vary in other embodiments depending on the desired numberof degrees of freedom for a surgical tool's end-effectors. In someembodiments, a surgical drape, coupled to a sterile adapter, may be usedto create a sterile boundary between the IDM 300 and the surgical tool.In these embodiments, the sterile adapter may be positioned between theattachment interface 310 and the surgical tool when the surgical tool issecured to the IDM 300, and the sterile adapter may be configured totransmit power from each torque coupler 314 to the respective instrumentinput.

The embodiment of the IDM 300 illustrated in FIG. 3 may be used invarious configurations with a surgical robotic system. The desiredconfiguration may depend on the type of surgical procedure beingperformed on a patient or the type of surgical tool being used duringthe surgical procedure. For example, the desired configuration of theIDM 300 may be different for an endoscopic procedure than for alaparoscopic procedure.

In a first configuration, the IDM 300 may be removeably or fixedlyattached to a surgical arm such that the attachment interface 310 isproximal to a patient during the surgical procedure. In thisconfiguration, hereinafter referred to as “front-mount configuration,”the surgical tool is secured to the IDM 300 on a side proximal to thepatient. A surgical tool for use with the front-mount configuration isstructured such that the elongated body of the surgical tool extendsfrom a side that is opposite of the attachment interface of the surgicaltool. As a surgical tool is removed from the IDM 300 in a front-mountconfiguration, the surgical tool will be removed in a proximal directionto the patient.

In a second configuration, the IDM 300 may be removeably or fixedlyattached to a surgical arm such that the attachment interface 310 isdistal to a patient during the surgical procedure. In thisconfiguration, hereinafter referred to as “back-mount configuration,”the surgical tool is secured to the IDM 300 on a side distal to thepatient. A surgical tool for use with the back-mount configuration isstructured such that the elongated body of the surgical tool extendsfrom the attachment interface of the surgical tool. This configurationincreases patient safety during tool removal from the IDM 300. As asurgical tool is removed from the IDM 300 in a back-mount configuration,the surgical tool will be removed in a distal direction from thepatient.

Certain configurations of a surgical tool may be structured such thatthe surgical tool can be used with an IDM in either a front-mountconfiguration or a back-mount configuration. In these configurations,the surgical tool includes an attachment interface on both ends of thesurgical tool. For some surgical procedures, the physician may decidethe configuration of the IDM depending on the type of surgical procedurebeing performed. For instance, the back-mount configuration may bebeneficial for laparoscopic procedures wherein laparoscopic tools may beespecially long relative to other surgical instruments. As a surgicalarm moves about during a surgical procedure, such as when a physiciandirects a distal end of the surgical tool to a remote location of apatient (e.g., a lung or blood vessel), the increased length oflaparoscopic tools causes the surgical arm to swing about a larger arc.Beneficially, the back-mount configuration decreases the effective toollength of the surgical tool by receiving a portion of the elongated bodythrough the passage 312 and thereby decreases the arc of motion requiredby the surgical arm to position the surgical tool.

FIGS. 5-6 illustrate perspective exploded views of an example surgicaltool 500 secured to the instrument device manipulator 300 of FIG. 3,according to one embodiment. The surgical tool 500 includes a housing502, an elongated body 504, and a plurality of instrument inputs 600. Aspreviously described, the elongated body 504 may be a laparoscope, anendoscope, or other surgical instrument having end-effectors. Asillustrated, the plurality of torque couplers 314 protrude outwards fromthe attachment interface 310 to engage with the instrument inputs 600 ofthe surgical tool. The structure of the instrument inputs 600 can beseen in FIG. 6, wherein the instrument inputs 600 have correspondinggeometry to the torque couplers 314 to ensure secure surgical toolengagement.

During a surgical procedure, a surgical drape may be used to maintain asterile boundary between the IDM 300 and an outside environment (i.e.,an operating room). In the embodiments of FIGS. 5-6, the surgical drapecomprises a sterile adapter 506, a first protrusion 508, and a secondprotrusion 510. While not shown in FIGS. 5-6, a sterile sheet isconnected to the sterile adapter and the second protrusion and drapesaround the IDM 300 to create the sterile boundary.

The sterile adapter 506 is configured to create a sterile interfacebetween the IDM 300 and the surgical tool 500 when secured to the IDM300. In the embodiment of FIGS. 5-6, the sterile adapter 506 has adisk-like geometry that covers the attachment interface 310 of the IDM300. The sterile adapter 506 comprises a central hole 508 that isconfigured to receive the elongated body 504 of the surgical tool 500.In this configuration, the sterile adapter 506 is positioned between theattachment interface 310 and the surgical tool 500 when the surgicaltool 500 is secured to the IDM 300, creating the sterile boundarybetween the surgical tool 500 and the IDM 300 and allowing the elongatedbody 504 to pass through the passage 312. In certain embodiments, thesterile adapter 506 may be capable of rotating with the surgical toolholder 308, transmitting the rotational torque from the plurality oftorque couplers 314 to the surgical tool 500, passing electrical signalsbetween the IDM 300 and the surgical tool 500, or some combinationthereof.

In the embodiment of FIGS. 5-6, the sterile adapter 506 furthercomprises a plurality of couplers 512. A first side of a coupler 512 isconfigured to engage with a respective torque coupler 314 while a secondside of a coupler 512 is configured to engage with a respectiveinstrument input 600. Similar to the structure of the plurality oftorque couplers 314, each coupler 512 is structured as a cylindricalprotrusion including a plurality of notches. Each side of the coupler512 has complementary geometry to fully engage with the respectivetorque coupler 314 and the respective instrument input 600. Each coupler512 is configured to rotate in a clockwise or counter-clockwisedirection with the respective torque coupler 314. This configurationallows each coupler 512 to transfer rotational torque from the pluralityof torque couplers 314 of the IDM 300 to the plurality of instrumentinputs 600 of the surgical tool 500, and thus control the end-effectorsof the surgical tool 500.

The first protrusion 508 and the second protrusion 510 are configured topass through the passage 312 of the IDM 300 and mate with each otherinside the passage 312. Each protrusion 508, 510 is structured to allowthe elongated body 504 to pass through the protrusion and thus thepassage 312. The connection of the first protrusion 508 and the secondprotrusion 510 creates the sterile boundary between the IDM 300 and theoutside environment (i.e., an operating room). The surgical drape isdiscussed in further detail with regards to FIGS. 13-16.

IV. Surgical Tool Disengagement

FIG. 7 illustrates a zoomed-in, perspective view of an actuationmechanism for engagement and disengagement of a surgical tool 500 from asterile adapter 506 of a surgical drape, according to one embodiment.Due to the configuration of the IDM 300 as described with regards toFIG. 3, the axis of surgical tool insertion into the patient during asurgical procedure is the same as the axis of surgical tool removal. Toensure patient safety during surgical tool removal, the surgical tool500 can be de-articulated from the sterile adapter 506 and the IDM 300before removing the surgical tool 500. In the embodiment of FIG. 7, theplurality of couplers 512 are configured to translate in an axialdirection, i.e., protract away from and retract towards the sterileadapter 506. The translation of the plurality of couplers 512 isactuated by the actuation mechanism which ensures de-articulation of thesurgical tool 500 by disengaging the plurality of couplers 512 from therespective instrument inputs 600. The actuation mechanism includes awedge 702 and a pusher plate 704.

The wedge 702 is a structural component that activates the pusher plate704 during the process of surgical tool disengagement. In the embodimentof FIG. 7, the wedge 702 is located within the housing 502 of thesurgical tool 500 along the outer perimeter of the housing 502. Asillustrated, the wedge 702 is oriented such that contact with the pusherplate 704 causes the pusher plate 704 to depress into the sterileadapter 506 if the housing 502 of the surgical tool 500 is rotatedclockwise relative to the sterile adapter 506. In alternate embodiments,the wedge 702 may be configured such that the housing 502 of thesurgical tool 500 is rotated counter-clockwise rather than clockwise.Geometries other than a wedge may be employed, such as an arch-shapedramp, given that the structure is able to depress the pusher plate whenrotating.

The pusher plate 704 is an actuator that disengages the plurality ofcouplers 512 from the surgical tool 500. Similar to the plurality oftorque couplers 314, each of the couplers 512 may be coupled to one ormore springs that bias each coupler 512 to spring outwards away from thesterile adapter 506. The plurality of couplers 512 are furtherconfigured to translate in an axial direction, i.e., protract away fromand retract into the sterile adapter 506. The pusher plate 704 actuatesthe translational movement of the couplers 512. As the pusher plate 704is depressed by the wedge 702, the pusher plate 704 causes the spring orplurality of springs coupled to each coupler 512 to compress, resultingin the couplers 512 retracting into the sterile adapter 506. In theembodiment of FIG. 7, the pusher plate 704 is configured to causesimultaneous retraction of the plurality of couplers 512. Alternateembodiments may retract the couplers 512 in a specific sequence or arandom order. In the embodiment of FIG. 7, the pusher plate 704 causesthe plurality of couplers 512 to partially retract into the sterileadapter 506. This configuration allows a surgical tool 500 to bede-articulated from the sterile adapter 506 before the surgical tool 500is removed. This configuration also allows a user to de-articulate thesurgical tool 500 from the sterile adapter 506 at any desired timewithout removing the surgical tool 500. Alternate embodiments may fullyretract the plurality of couplers 512 into the sterile adapter 506 suchthat the effective height of each coupler 512 measured is zero. In someembodiments, the pusher plate 704 may cause the plurality of torquecouplers 314 to retract synchronously with the plurality of respectivecouplers 512.

FIGS. 8A and 8B illustrate a process of engaging and disengaging asurgical tool from a sterile adapter, according to one embodiment. FIG.8A illustrates a sterile adapter 506 and a surgical tool 500 in asecured position, such that the two components are secured together andthe plurality of couplers 512 are fully engaged with respectiveinstrument inputs 600 of the surgical tool 500. To achieve the securedposition as illustrated in FIG. 8A, the elongated body 504 (not shown)of the surgical tool 500 is passed through the central hole 508 (notshown) of the sterile adapter 506 until mating surfaces of the surgicaltool 500 and the sterile adapter 506 are in contact, and the surgicaltool 500 and the sterile adapter 506 are secured to each other by alatching mechanism. In the embodiments of FIGS. 8A and 8B, the latchingmechanism comprises a ledge 802 and a latch 804.

The ledge 802 is a structural component that secures the latch 804 inthe secured position. In the embodiment of FIG. 8A, the ledge 802 islocated within the housing 502 of the surgical tool 500 along the outerperimeter of the housing 502. As illustrated in FIG. 8A, the ledge 802is oriented such that it rests below a protrusion on the latch 804,preventing the latch 804 and thereby the sterile adapter 506 frompulling away from the surgical tool 500 due to the sprung-up nature ofthe plurality of couplers 512, as described with regards to FIG. 7.

The latch 804 is a structural component that mates with the ledge 802 inthe secured position. In the embodiment of FIG. 8A, the latch 804protrudes from the mating surface of the sterile adapter 506. The latch804 comprises a protrusion that is configured to rest against the ledge802 when the surgical tool 500 is secured to sterile adapter 506. In theembodiment of FIG. 8A, the housing 502 of the surgical tool 500 iscapable of rotating independent of the rest of the surgical tool 500.This configuration allows the housing 502 to rotate relative to thesterile adapter 506 such that the ledge 802 is secured against the latch804, thereby securing the surgical tool 500 to the sterile adapter 502.In the embodiment of FIG. 8A, the housing 502 is rotatedcounter-clockwise to achieve the secured position, but other embodimentsmay be configured for clockwise rotation. In alternate embodiments, theledge 802 and the latch 804 may have various geometries that lock thesterile adapter 506 and the surgical tool 500 in the secured position.

FIG. 8B illustrates the sterile adapter 506 and the surgical tool 500 inan unsecured position, in which the surgical tool 500 may be removedfrom the sterile adapter 506. As previously described, the housing 502of the surgical tool 500 is capable of rotating independent of the restof the surgical tool 500. This configuration allows the housing 502 torotate even while the plurality of couplers 512 are engaged with theinstrument inputs 600 of the surgical tool 500. To transition from thesecured position to the unsecured position, a user rotates the housing502 of the surgical tool 500 clockwise relative to the sterile adapter506. During this rotation, the wedge 702 contacts the pusher plate 704and progressively depresses the pusher plate 704 as it slides againstthe angled plane of the wedge 702, thereby causing the plurality ofcouplers 512 to retract into the sterile adapter 506 and disengage fromthe plurality of instrument inputs 600. Further rotation causes thelatch 804 to contact an axial cam 806, which is structured similar towedge 702. As the latch 804 contacts the axial cam 806 during rotation,the axial cam 806 causes the latch 804 to flex outwards away from thesurgical tool 500 such that the latch 804 is displaced from the ledge802. In this unsecured position, the plurality of couplers 512 areretracted, and the surgical tool 500 can be removed from the sterileadapter 506, in the embodiment of FIG. 8B. In other embodiments, theaxial cam 806 may have various geometries such that rotation causes thelatch 804 to flex outwards.

In alternate embodiments, the direction of rotation of the housing 502of the surgical tool 500 may be configured as counter-clockwise rotationto unsecure the latch 804 from the ledge 802. Additionally, alternateembodiments may include similar components but the location of thecomponents may be switched between the sterile adapter 506 and thesurgical tool 500. For example, the ledge 802 may be located on thesterile adapter 506 while the latch 804 may be located on the surgicaltool 500. In other embodiments, an outer portion of the sterile adapter506 may be rotatable relative to the plurality of couplers 512 ratherthan the housing 502 of the surgical tool 500. Alternate embodiments mayalso include a feature to lock the rotation of the housing 502 of thesurgical tool 502 when the housing 502 is fully rotated relative to theinstrument inputs 600. This configuration prevents rotation of thesurgical tool if the instrument inputs 600 have been de-articulated fromthe couplers 512. In some embodiments, the retraction and protraction ofthe couplers 512 may be coupled with a respective retraction andprotraction of the torque couplers 314, such that a coupler 512 engagedwith a torque coupler 314 will translate together.

FIGS. 9A and 9B illustrate a process of surgical tool engagement anddisengagement of a surgical tool from a sterile adapter, according toanother embodiment. In the embodiment of FIGS. 9A and 9B, a sterileadapter 900 may include an outer band 902 that secures the surgical tool904 to the sterile adapter 900. As illustrated in FIGS. 9A and 9B, thesurgical tool 902 comprises a ramp 906 on the outer surface of thehousing 908. The ramp 906 includes a notch 910 that is configured toreceive a circular protrusion 912, which is positioned on an innersurface of the outer band 902 of the sterile adapter 900. The outer band902 is capable of rotating independent of and relative to the sterileadapter 900 and the surgical tool 904. As the outer band 902 rotates ina first direction, the circular protrusion 912 glides up the surface ofthe ramp 906 until the circular protrusion 912 is nested within thenotch 910, thereby securing the sterile adapter 900 and the surgicaltool 904 together. Rotation of the outer band 902 in a second directioncauses the sterile adapter 900 and the surgical tool 904 to unsecurefrom each other. In certain embodiments, this mechanism may be coupledwith a de-articulation of the plurality of couplers 914 on the sterileadapter 900, as described with regards to FIGS. 7-8.

Alternate embodiments of surgical tool disengagement may includeadditional features, such as an impedance mode. With an impedance mode,the surgical robotics system may control whether the surgical tool canbe removed from the sterile adapter by a user. The user may initiate thedisengagement mechanism by rotating the outer housing of the surgicaltool and unsecuring the surgical tool from the sterile adapter, but thesurgical robotics system may not release the couplers from theinstrument inputs. Only once the surgical robotics system hastransitioned into the impedance mode are the couplers released and theuser can remove the surgical tool. An advantage of keeping the surgicaltool engaged is that the surgical robotics system can control theend-effectors of the surgical tool and position them for tool removalbefore the surgical tool is removed to minimize damage to the surgicaltool. To activate an impedance mode, the pusher plate 704 may have ahard-stop such that the pusher plate can be depressed up to a certaindistance. In some embodiments, the hard-stop of the pusher plate may beadjustable such that the hard-stop coincides with the maximum amount ofrotation of the housing of the surgical tool. Thus, once the fullrotation is reached, the hard-stop is also met by the pusher plate. Aplurality of sensors may detect these events and trigger the impedancemode.

Certain situations may require emergency tool removal during a surgicalprocedure in which the impedance mode may not be desirable. In someembodiments, the hard-stop of the pusher plate may have compliance, suchthat the hard-stop may yield in an emergency situation. The hard-stop ofthe pusher plate may be coupled to a spring, allowing the hard-stop toyield in response to additional force. In other embodiments, thehard-stop of the pusher plate may be rigid such that emergency toolremoval occurs by removing the latch that secures the surgical tool tothe sterile adapter.

V. Roll Mechanism

FIG. 10A illustrates a perspective view of a mechanism for rolling asurgical tool holder 308 within an instrument device manipulator 300,according to one embodiment. As illustrated in FIG. 10A, the attachmentinterface 310 is removed to expose the roll mechanism. This mechanismallows the surgical tool holder 308 to continuously rotate or “roll”about the rotational axis 316 in either direction. The roll mechanismcomprises a stator gear 1002 and a rotor gear 1004.

The stator gear 1002 is a stationary gear configured to mate with therotor gear 1004. In the embodiment of FIG. 10A, the stator gear 1002 isa ring-shaped gear comprising gear teeth along the inner circumferenceof the ring. The stator gear 1002 is fixedly attached to the outerhousing 306 behind the attachment interface 310. The stator gear 1002has the same pitch as the rotor gear 1004, such that the gear teeth ofthe stator gear 1002 are configured to mate with the gear teeth of therotor gear 1004. The stator gear 1002 may be composed of rigid materials(e.g., metals or hard plastics).

The rotor gear 1004 is a rotating gear configured to induce rotation ofthe surgical tool holder 308. As illustrated in FIG. 10A, the rotor gear1004 is a circular gear comprising gear teeth along its outercircumference. The rotor gear 1004 is positioned behind the attachmentinterface 310 and within the inner circumference of the stator gear 1002such that the gear teeth of the rotor gear 1004 mate with the gear teethof the stator gear. As previously described, the rotor gear 1004 and thestator gear 1002 have the same pitch. In the embodiment of FIG. 10A, therotor gear 1004 is coupled to a drive mechanism (e.g., a motor) thatcauses the rotor gear 1004 to rotate in a clockwise or counter-clockwisedirection. The drive mechanism may receive signals from an integratedcontroller within the surgical tool holder assembly 304. As the drivemechanism causes the rotor gear 1004 to rotate, the rotor gear 1004travels along the gear teeth of the stator gear 1002, thereby causingthe surgical tool holder 308 to rotate. In this configuration, the rotorgear 1004 is capable of continuously rotating in either direction andthus allows the surgical tool holder 308 to achieve infinite roll aboutthe rotational axis 316. Alternate embodiments may use similarmechanisms to allow for infinite roll, such as a configuration of a ringgear and a pinion gear.

FIG. 10B illustrates a cross-sectional view of an instrument devicemanipulator 300, according to one embodiment. As illustrated in FIB.10B, the roll mechanism is coupled with a plurality of bearing 1006. Abearing is a mechanical component that reduces friction between movingparts and facilitates rotation around a fixed axis. One bearing alone iscapable of supporting the radial or torsional loading as the surgicaltool holder 308 rotates within the outer housing 306. In the embodimentof FIG. 10B, the IDM 300 includes two bearings 1006 a, 1006 b fixedlyattached to the surgical tool holder 308 such that a plurality ofcomponents (such as balls or cylinders) within the bearings 1006contacts the outer housing 306. A first bearing 1006 a is secured at afirst end behind the attachment interface 310 and a second bearing 1006b is secured at a second end. This configuration improves rigidity andsupport between the first end and the second end of the surgical toolholder 308 as the surgical tool holder 308 rotates within the outerhousing 306. Alternate embodiments may include additional bearings thatprovide additional support along the length of the surgical tool holder.

FIG. 10B also illustrates sealing components within the IDM 300,according to one embodiment. The IDM 300 comprises a plurality ofO-rings 1008 and a plurality of gaskets 1010 which are configured toseal a junction between two surfaces to prevent fluids from entering thejunction. In the embodiment of FIG. 10B, the IDM includes O-rings 1008a, 1008 b, 1008 c, 1008 d, 1008 e between junctions of the outer housingand gaskets 1010 a, 1010 b between junctions within the surgical toolholder 308. This configuration helps to maintain sterility of thecomponents within the IDM 300 during a surgical procedure. Gaskets andO-rings are typically composed of strong elastomeric materials (e.g.,rubber).

VI. Electrical Componentry

FIG. 11A illustrates a partially exploded, perspective view of theinternal components of an instrument device manipulator and certainelectrical components thereof, according to one embodiment. The internalcomponents of the surgical tool holder 308 include a plurality ofactuators 1102, a motor, a gearhead (not shown), a torque sensor (notshown), a torque sensor amplifier 1110, a slip ring 1112, a plurality ofencoder boards 1114, a plurality of motor power boards 1116, and anintegrated controller 1118.

The plurality of actuators 1102 drive the rotation of each of theplurality of torque couplers 314. In the embodiment of FIG. 11A, anactuator, such as 1102 a or 1102 b, is coupled to a torque coupler 314via a motor shaft. The motor shaft may be a keyed shaft such that itincludes a plurality of grooves to allow the motor shaft to securelymate to a torque coupler 314. The actuator 1102 causes the motor shaftto rotate in a clockwise or counter-clockwise direction, thereby causingthe respective torque coupler 314 to rotate in that direction. In someembodiments, the motor shaft may be torsionally rigid but springcompliant, allowing the motor shaft and thus the torque coupler 314 torotate and to translate in an axial direction. This configuration mayallow the plurality of torque couplers 314 to retract and protractwithin the surgical tool holder 308. Each actuator 1102 may receiveelectrical signals from the integrated controller 1118 indicating thedirection and amount to rotate the motor shaft. In the embodiment ofFIG. 11A, the surgical tool holder 308 includes five torque couplers 314and thus five actuators 1102.

The motor drives the rotation of the surgical tool holder 308 within theouter housing 306. The motor may be structurally equivalent to one ofthe actuators, except that it is coupled to the rotor gear 1004 andstator gear 1002 (see FIG. 10A) for rotating the surgical tool holder308 relative to the outer housing 306. The motor causes the rotor gear1004 to rotate in a clockwise or counter-clockwise direction, therebycausing the rotor gear 1004 to travel about the gear teeth of the statorgear 1002. This configuration allows the surgical tool holder 308 tocontinuously roll or rotate without being hindered by potential wind-upof cables or pull-wires. The motor may receive electrical signals fromthe integrated controller 1118 indicating the direction and amount torotate the motor shaft.

The gearhead controls the amount of torque delivered to the surgicaltool 500. For example, the gearhead may increase the amount of torquedelivered to the instrument inputs 600 of the surgical tool 500.Alternate embodiments may be configured such that the gearhead decreasesthe amount of torque delivered to the instrument inputs 600.

The torque sensor measures the amount of torque produced on the rotatingsurgical tool holder 308. In the embodiment shown in FIG. 11A, thetorque sensor is capable of measuring torque in the clockwise and thecounter-clockwise direction. The torque measurements may be used tomaintain a specific amount of tension in a plurality of pull-wires of asurgical tool. For instance, some embodiments of the surgical roboticssystem may have an auto-tensioning feature, wherein, upon powering onthe surgical robotics system or engaging a surgical tool with an IDM,the tension on the pull-wires of the surgical tool will be pre-loaded.The amount of tension on each pull-wire may reach a threshold amountsuch that the pull-wires are tensioned just enough to be taut. Thetorque sensor amplifier 1110 comprises circuitry for amplifying thesignal that measures the amount of torque produced on the rotatingsurgical tool holder 308. In some embodiments, the torque sensor ismounted to the motor.

The slip ring 1112 enables the transfer of electrical power and signalsfrom a stationary structure to a rotating structure. In the embodimentof FIG. 11A, the slip ring 1112 is structured as a ring including acentral hole that is configured to align with the passage 312 of thesurgical tool holder 308, as is also shown in an additional perspectiveview of the slip ring 1112 in FIG. 11B. A first side of the slip ring1112 includes a plurality of concentric grooves 1120 while a second sideof the slip ring 1112 includes a plurality of electrical components forthe electrical connections provided from the surgical arm and the base302, as described with regards to FIG. 3. The slip ring 1112 is securedto the outer housing 306 of the surgical tool holder 308 at a specificdistance from the outer housing 306 to allocate space for theseelectrical connections. The plurality of concentric grooves 1120 areconfigured to mate with a plurality of brushes 1122 attached to theintegrated controller. The contact between the grooves 1120 and thebrushes 1122 enables the transfer of electrical power and signals fromthe surgical arm and base to the surgical tool holder.

The plurality of encoder boards 1114 read and process the signalsreceived through the slip ring from the surgical robotic system. Signalsreceived from the surgical robotic system may include signals indicatingthe amount and direction of rotation of the surgical tool, signalsindicating the amount and direction of rotation of the surgical tool'send-effectors and/or wrist, signals operating a light source on thesurgical tool, signals operating a video or imaging device on thesurgical tool, and other signals operating various functionalities ofthe surgical tool. The configuration of the encoder boards 1114 allowsthe entire signal processing to be performed completely in the surgicaltool holder 308. The plurality of motor power boards 1116 each comprisescircuitry for providing power to the motors.

The integrated controller 1118 is the computing device within thesurgical tool holder 308. In the embodiment of FIG. 11A, the integratedcontroller 1118 is structured as a ring including a central hole that isconfigured to align with the passage 312 of the surgical tool holder308. The integrated controller 1118 includes a plurality of brushes 1122on a first side of the integrated controller 1118. The brushes 1122contact the slip ring 1112 and receive signals that are delivered fromthe surgical robotics system through the surgical arm, the base 302, andfinally through the slip ring 1112 to the integrated controller 1118. Asa result of the received signals, the integrated controller 1118 isconfigured to send various signals to respective components within thesurgical tool holder 308. In some embodiments, the functions of theencoder boards 1114 and the integrated controller 1118 may bedistributed in a different manner than is described here, such that theencoder boards 1114 and the integrated controller 1118 may perform thesame functions or some combination thereof.

FIG. 11B illustrates a partially exploded, perspective view of theinternal components of an instrument device manipulator and certainelectrical components thereof, according to one embodiment. Theembodiment of FIG. 11B includes two encoder boards 1114 a and 1114 b, atorque sensor amplifier 1110, and three motor power boards 1116 a, 1116b, and 1116 c. These components are secured to the integrated controller1118 and protrude outwards, extending perpendicularly from theintegrated controller 1118. This configuration provides room for theplurality of actuators 1102 and motor to be positioned within theelectrical boards.

As discussed with regards to FIG. 11A, the slip ring 1112 is secured ata specific distance from the outer housing 306. To ensure correct spaceallocation between the slip ring 1112 and the outer housing 306 for theelectrical connections from the surgical arm and base 302 to the slipring 1112, in the embodiment of FIG. 11B, the slip ring 1112 issupported by a plurality of alignment pins, a plurality of coil springs,and a shim. The slip ring 1112 includes a hole 1124 on each side of thecenter hole of the slip ring 1112 that is configured to accept a firstside of an alignment pin while a second side of the alignment pin isinserted into a respective hole in the outer housing 306. The alignmentpins may be composed of rigid materials (e.g., metal or hard plastics).The plurality of coil springs are secured around the center of the slipring 1112 and configured to bridge the space and maintain contactbetween the slip ring 1112 and the outer housing 306. The coil springsmay beneficially absorb any impact to the IDM 300. The shim isring-shaped spacer that is positioned around the center hole of the slipring 1112 to add further support between the slip ring 1112 and theouter housing 306. In addition, these components provide stability tothe slip ring 1112 as the plurality of brushes 1122 on the integratedcontroller 1118 contact and rotate against the plurality of concentricgrooves 1120. In alternate embodiments, the number of alignment pins,coil springs, and shims may vary until the desired support between theslip ring 1112 and the outer housing 306 is achieved.

FIG. 12 illustrates a zoomed-in, perspective view of electricalcomponents of an instrument device manipulator 300 for roll indexing thesurgical tool holder 308, according to one embodiment. Roll indexingmonitors the position of the surgical tool holder 308 relative to theouter housing 306 such that the position and orientation of the surgicaltool 500 is continuously known by the surgical robotics system. Theembodiment of FIG. 12 includes a micro switch 1202 and a boss 1204. Themicro switch 1202 and the boss 1204 are secured within the surgical toolholder 308. The boss 1204 is a structure on the outer housing 306 thatis configured to contact the micro switch 1202 as the surgical toolholder 308 rotates, thus activating the micro switch each time there iscontact with the boss 1204. In the embodiment of FIG. 12, there is oneboss 1204 that serves as a single reference point for the micro switch1202.

VII. Surgical Drape

FIG. 13 illustrates a cross-sectional view of a surgical drape for aninstrument device manipulator for a surgical robotics system, accordingto one embodiment. The surgical drape 1300 provides a sterile boundaryfor the IDM, the surgical arm, and other portions of the surgicalrobotics system during a surgical procedure. In the embodiment of FIG.13, the surgical drape 1300 is configured for use with an IDM thatincludes a passage configured to receive an elongated body of a surgicaltool when the surgical tool is attached to the IDM, such as IDM 300. Thesurgical drape 1300 comprises a sterile sheet 1302, a first protrusion1304, and a second protrusion 1306.

The sterile sheet 1302 creates and maintains a sterile environment forportions of the surgical robotics system during a surgical procedure. Inthe embodiment of FIG. 13, the sterile sheet 1302 is configured to coverthe IDM 300, the surgical arm, and portions of the surgical roboticssystem. The sterile sheet 1302 may be composed of a variety ofmaterials, such as plastics (e.g., polypropylene), paper, and othermaterials that may be resistant to fluids.

The first protrusion 1304 is a cylindrical tube configured to receive anelongated body of a surgical tool, such as elongated body 504 ofsurgical tool 500. In the embodiment of FIG. 13, the first protrusion1304 is connected to a first portion of the sterile sheet 1302, and afirst end of the first protrusion 1304 is configured to be inserted intoa first end of the passage 312. The first end of the first protrusion1304 includes a mating interface 1308 that is configured to mate with areciprocal mating interface 1310 on the second protrusion 1306. Thefirst protrusion 1304 may be composed of rigid materials (e.g., metalsor hard plastics).

The second protrusion 1306 is a cylindrical tube configured to receivean elongated body of a surgical tool, such as elongated body 504 ofsurgical tool 500. In the embodiment of FIG. 13, the second protrusion1306 is connected to a second portion of the sterile sheet 1302, and afirst end of the second protrusion 1306 is configured to be insertedinto a second end of the passage 312, such that the first protrusion1304 and the second protrusion 1306 are inserted into opposite ends ofthe passage 312. The first end of the second protrusion 1306 includes areciprocal mating interface 1310 that is configured to removeably couplewith the mating interface 1308 on the first protrusion 1304 inside thepassage 312. When coupled to each other, the mating interface 1308 andthe reciprocal mating interface 1310 create a sterile junction. Thesecond protrusion 1306 may be composed of rigid materials (e.g., metalsor hard plastics). In alternate embodiments, coupling mechanisms mayinclude hook-and-loop fasteners, friction-fit tubes, threaded tubes, andother suitable coupling mechanisms.

FIG. 14 illustrates a cross-sectional view of reciprocal matinginterfaces of a surgical drape for a surgical tool holder, according toone embodiment. As described with regards to FIG. 13, the first end ofthe first protrusion 1304 includes a mating interface 1308. The matinginterface 1308 is structured as two concentric tubes with a crevicebetween the concentric tubes, as shown by the cross-section in FIG. 14,wherein the crevice is a ring configured to receive an end of anothertube. In the embodiment of FIG. 14, the reciprocal mating interface 1310at the first end of the second protrusion 1306 is structured as a tubethat tapers such that the diameter at the first end of the tube issmaller relative to the rest of the tube. The tapered end facilitateseasy insertion of the reciprocal mating interface 1310 into the matinginterface 1308. In addition, it is possible for the inner surfaces ofthe first protrusion 1304 and the second protrusion 1306 to contact anunsterile surface while the outer surfaces are able to remain sterile.The junction between the mating interface 1308 and the reciprocal matinginterface 1310 when secured to each other creates a convoluted path byenveloping the first end of the second protrusion 1306 into the crevice.This configuration ensures that any surfaces of the first protrusion1304 or the second protrusion 1306 that contacted an unsterile surfaceare enveloped within the junction. This configuration further ensuresthat any fluids may not be able to travel across the junction betweenthe inner surfaces and the outer surfaces and that a sterile environmentis maintained for the IDM and other portions of the surgical roboticssystem. In some embodiments, the junction between the mating interface1308 and the reciprocal mating interface 1310 may further comprise agasket to prevent fluids from penetrating the junction.

In some embodiments of the surgical drape, the surgical drape 1300 mayfurther include a plurality of sterile adapters 1400 that provide asterile boundary between the IDM and the outside environment or thesurgical tool. In certain embodiments, the sterile adapter 1400 isconfigured to accommodate a rotating interface of an IDM, such as IDM300. In the embodiment of FIG. 14, the sterile adapter 1400 comprises anouter ring 1402 and an inner disk 1404. The outer ring 1402 is connectedto the sterile sheet 1302, and the inner disk 1404 is connected to thefirst protrusion 1304, as illustrated in FIG. 14. The inner disk 1404 isrotatably secured within the outer ring 1402. In the embodiment of FIG.14, the sterile adapter 1400 covers the attachment interface 310 of theIDM 300 such that the sterile adapter 1400 is positioned between theattachment interface 310 and a surgical tool 500 when the surgical tool500 is secured to the IDM 300. This configuration of the sterile adapter1400 may allow the inner disk 1404 or the outer ring 1402 to freelyrotate with the rotation of the IDM 300 and the surgical tool 500. Theouter ring 1402 and the inner disk 1404 may be composed of rigidmaterials (e.g., metals or hard plastics). In alternate embodiments,portions of the inner disk may be a membrane that covers the pluralityof torque couplers of the IDM.

FIG. 15 illustrates a cross-sectional view of sterile adapters of asurgical drape for an instrument device manipulator, according to oneembodiment. As described in regards to FIG. 14, the surgical drape 1300may include a plurality of sterile adapters, such as 1400 and 1406, thatare configured to accommodate a rotating interface of an IDM 300. In theembodiment of FIG. 15, a sterile adapter 1400, 1406 is positioned ateach end of the IDM 300. A sterile adapter 1406 that is configured tocover the end of the IDM 300 without the attachment interface 310 mayvary in structure from a sterile adapter 1400 that is configured tocover the attachment interface 310, i.e., the sterile adapter may notneed structures to accommodate for the plurality of torque couplers 314.In alternate embodiments, portions of the first protrusion 1304 or thesecond protrusion 1306 may include a rotatable component, such as aroller bearing or a similar inner disk and outer ring mechanism aspreviously described, such that rotation occurs within the passage 312rather than at a sterile adapter. This configuration may improvestability during rotation of the surgical tool holder 308 due to thesmaller diameter of the protrusion compared to the diameter of the innerdisk 1402. This configuration may also eliminate the need for anadditional sterile adapter 1406 at the end of the IDM 300 without theattachment interface 310.

FIG. 16 illustrates a cross-sectional view of a surgical drape for aninstrument device manipulator, according to an additional embodiment. Asillustrated in FIG. 16, the surgical drape 1300 provides a sterileboundary for the IDM and the surgical arm. The embodiment of FIG. 16illustrates the inner disk 1404 through which respective torque couplers314 may protrude.

VIII. Power and Data Transmission

FIG. 17 illustrates an optical interface for power and data transmissionbetween a surgical tool and an instrument device manipulator, accordingto one embodiment. In certain embodiments, surgical tools may havecapabilities that require power and/or data transmission, such as acamera or a light source that operates at the proximal end of theelongated body of the surgical tool. Other features may include trackingsensors or tension sensors. Surgical tools with such features may usecable connections to the rest of the platform for power and/or datatransmission and thus hinder the surgical tool's capability to roll. Toachieve infinite roll for these surgical tools, power and/or datatransmission may occur through inductive power and an optical interface.

In the embodiment of FIG. 17, the IDM 1700 includes a power transmitter,and the surgical tool includes a power receiver. The power transmitterinductively transmits power to the power receiver across the attachmentinterface 310 without the need for direct connections. In the embodimentof FIG. 17, a plurality of coils are secured within the IDM 1700perpendicular to the attachment interface 310 and centered along therotational axis of the IDM 1700. The coils are coupled to the integratedcontroller and configured to receive signals to transmit power. Thecoils may be of various diameters centered around the passage 312 of theIDM 1700. A larger diameter may improve the power transmissioncapabilities. The surgical tool 1704 may include a battery to supportthe instrument operation in the event that the wireless powertransmission is interrupted. In some embodiments, the power transmittermay have shielding to prevent transferring heat to nearby metalcomponents and interfering with the motors in the IDM 1700. Possibleshielding materials include mu-metals.

In the embodiment of FIG. 17, the optical interface is between themating surfaces of the IDM 1700 and the surgical tool 1704. The IDM 1700and the surgical tool 1704 each include a plurality of opticaltransmitters, such as 1706 a, 1706 b, and a plurality of opticalreceivers, such as 1708 a, 1708 b. In the embodiment of FIG. 17, thereis at least one pair for the connection between the surgical tool 1704to the IDM 1700 for transferring data such as imaging data, and at leastone pair for the connection between the IDM 1700 to the surgical tool1704. In addition, a wireless point-to-point data connection can be usedfor high bandwidth communication from the IDM 1700 to the surgicalrobotic system. In some embodiments, the power transmitter may be anLED, which would require the sterile sheet across the attachmentinterface to be composed of a material transparent to the LED light.Alternate embodiments may use RFID technology or physical connectionsbetween the IDM 1700 and surgical tool 1704 for data transmission.

In some embodiments, the optical transmitters 1706 and optical receivers1708 are symmetrically oriented with respect to the plurality ofinstrument inputs 1710 and the plurality of torque couplers 1712,respectively, such that the surgical tool 1704 may be attached to thesurgical tool holder 1702 in any orientation. Once the surgical tool1704 is attached to the surgical tool holder 1702, an opticaltransmitter 1706 of the surgical tool 1704 may be configured to transmita signal to an optical receiver 1708. The signal can be used todetermine the rotational orientation of the surgical tool 1704 withrespect to the surgical tool holder 1702. Once the rotationalorientation of the surgical tool 1704 has been determined, the opticaldata flow can be fully established and the actuators for the torquecouplers 1712 can be accurately controlled.

IX. Alternative Considerations

Upon reading this disclosure, those of skill in the art will appreciatestill additional alternative structural and functional designs throughthe disclosed principles herein. Thus, while particular embodiments andapplications have been illustrated and described, it is to be understoodthat the disclosed embodiments are not limited to the preciseconstruction and components disclosed herein. Various modifications,changes and variations, which will be apparent to those skilled in theart, may be made in the arrangement, operation and details of the methodand apparatus disclosed herein without departing from the spirit andscope defined in the appended claims.

As used herein any reference to “one embodiment” or “an embodiment”means that a particular element, feature, structure, or characteristicdescribed in connection with the embodiment is included in at least oneembodiment. The appearances of the phrase “in one embodiment” in variousplaces in the specification are not necessarily all referring to thesame embodiment.

Some embodiments may be described using the expression “coupled” and“connected” along with their derivatives. For example, some embodimentsmay be described using the term “coupled” to indicate that two or moreelements are in direct physical or electrical contact. The term“coupled,” however, may also mean that two or more elements are not indirect contact with each other, but yet still co-operate or interactwith each other. The embodiments are not limited in this context unlessotherwise explicitly stated.

As used herein, the terms “ comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,method, article, or apparatus that comprises a list of elements is notnecessarily limited to only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive or and not to an exclusive or. For example,a condition A or B is satisfied by any one of the following: A is true(or present) and B is false (or not present), A is false (or notpresent) and B is true (or present), and both A and B are true (orpresent).

In addition, use of the “a” or “an” are employed to describe elementsand components of the embodiments herein. This is done merely forconvenience and to give a general sense of the invention. Thisdescription should be read to include one or at least one and thesingular also includes the plural unless it is obvious that it is meantotherwise.

1. A surgical instrument device manipulator comprising: a surgical armoperable by a surgical robotics system; a base fixedly connected to thesurgical arm; a surgical tool holder assembly that is rotatably mountedto the base, the surgical tool holder assembly including a surgical toolholder configured to removeably attach to a surgical tool such that thesurgical tool is fixed to the surgical tool holder when the surgicaltool is attached; and at least one drive mechanism coupled between thebase and the surgical tool holder assembly to rotate the surgical toolholder assembly relative to the base.
 2. (canceled)
 3. (canceled)
 4. Thesurgical instrument device manipulator of claim 1, wherein the surgicaltool comprises a lumen that is co-axially aligned with a rotational axisof the drive mechanism.
 5. (canceled)
 6. (canceled)
 7. The surgicalinstrument device manipulator of claim 1, further comprising: aplurality of slip rings configured to deliver electrical power andsignals from the base to the surgical tool holder.
 8. The surgicalinstrument device manipulator of claim 1, wherein the surgical toolholder assembly comprises a stator gear that is structured as a ringincluding gear teeth along the inner circumference of the ring, wherethe stator gear is configured to remain stationary relative to thesurgical tool holder.
 9. The surgical instrument device manipulator ofclaim 1, wherein the drive mechanism is coupled to a rotor gear that isconfigured to mate with the stator gear of the surgical tool holderassembly such that rotation of the rotor gear causes the surgical toolholder to rotate relative to the stator gear.
 10. The surgicalinstrument device manipulator of claim 1, wherein a plurality of encoderboards are secured within the surgical tool holder, each encoder boardis configured to read and process signals relayed through the slip ring.11. The surgical instrument device manipulator of claim 1, wherein aplurality of ball bearings within the surgical tool holder assemblyfacilitate rotation of the surgical tool holder about the rotationalaxis.
 12. The surgical instrument device manipulator of claim 1, whereinthe manipulator comprises a power transmitter and the surgical toolcomprises a power receiver configured to receive power inductively fromthe power transmitter.
 13. (canceled)
 14. The surgical instrument devicemanipulator of claim 1, wherein the manipulator comprises a plurality ofoptical transmitters and a plurality of optical receivers, and thesurgical tool comprises a plurality of respective optical transmittersand a plurality of respective optical receivers.
 15. The surgicalinstrument device manipulator of claim 1, wherein at least one pair ofan optical transmitter and an optical receiver is configured to transferdata from the surgical tool to the manipulator.
 16. The surgicalinstrument device manipulator of claim 1, wherein at least one pair ofan optical transmitter and an optical receiver is configured to transferdata from the manipulator to the surgical tool.
 17. The surgicalinstrument device manipulator of claim 1, wherein a wirelesspoint-to-point data connection is used for high bandwidth communicationfrom the manipulator to the surgical robotic system.
 18. (canceled) 19.The surgical instrument device manipulator of claim 1, wherein anoptical transmitter of the surgical tool may be configured to transmit asignal to an optical receiver of the surgical tool holder, wherein thesignal is used to determine the orientation of the surgical tool withrespect to the surgical tool holder.
 20. The surgical instrument devicemanipulator of claim 1, wherein a surgical drape for the surgicalinstrument device manipulator comprises a sterile adapter that ispositioned between the surgical tool holder and the surgical toolattached to the surgical tool holder via the attachment interface, thesterile adapter configured to rotatably secure to the surgical toolholder.
 21. The system of claim 1, wherein the sterile adapter iscapable of transmitting data, power, and electrical signals between thesurgical tool holder and the surgical tool.
 22. The system of claim 1,further comprising an outer housing that is stationary with respect baseand provide supports for the surgical tool assembly.
 23. The system ofclaim 22, wherein the surgical holder rotates independently of the outerhousing.
 24. The system of claim 22, wherein the outer housing fullycircumscribes the surgical holder.
 25. The system of claim 1, whereinthe surgical tool holder comprises at least one torque coupler that isconfigured to engage with a respective instrument input on the surgicaltool.
 26. The system of claim 25 further comprising a surgical tool andwherein rotation of the at least one torque coupler causes rotation ofthe respective instrument input of the surgical tool to control anend-effector of the surgical tool.
 27. The system of claim 25, whereinan outer surface of the at least one torque coupler includes a spineinterface.